Strange knocking/rattle sounds (transmission, drivetrain) ??? - EDITED [springs knocking]

1373 Views 32 Replies 6 Participants Last post by Wojtas, 1 mo ago

Wojtas

Discussion Starter · 2 mo ago

Hi Guys,

Starting this morning I noticed very odd rattle/knocking sounds. I know that it is very hard to describe using the words but I will try.

Before I will start, few words to have a better picture:

*40k mileage
* all fluids are fine (PTU, oil, transmission fluid)

Few days ago I changed the springs and brake kit but I do not think it is connected with this strange noises.
(I did not hear this before after spring and brakes replacement - it is just started this morning)
however I have some issue with my parking brake ( I will add this part tomorrow)

For me personally it seems like a sound from transmission or drivetrain, like car wants to change the gear or something. I can hear it when i drive slowly, when I accelerate, but also it happened when the car is stationary.

The sound is more hearable from the cabin
The sound is very disturbing (I'm going to the mechanic tomorrow)😔 I recorded it - I will try to upload here somehow.

I have clean the bugs in FORSCAN, it is clean, cannot find any issue while checking with FORSCAN.

I will keep you posted. Maybe it will be useful for some of you.
I hope it's nothing serious😔

I will be very grateful for any hints/tips that you always have!

1 - 20 of 33 Posts

Wojtas

Discussion Starter · #2 · 2 mo ago

Recorded sound:

Vocaroo | Online voice recorder

Vocaroo is a quick and easy way to share voice messages over the interwebs.

vocaroo.com

Wojtas

Discussion Starter · #3 · 2 mo ago

I put the phone while recording under the steering wheel - I cannot hear that sound well from outside and under the hood

maydk65

· #4 · 2 mo ago

Do you feel any strange vibrations in the gas petal? brake? Steering Wheel? Doesn't really sound metallic. Sounds more like something loose. Are all the under car panels secured? Broken rear trans mount?

ZenFFS

· #5 · 2 mo ago

Sorry to hear this,,, literally. I have no solution, but to help narrow it down:

When stationary and you hear it, are you in Drive?,, or N, or P?
Do you only hear it while in D?
Happen while you 'roll' in N?
Stock Tune?
If you turn OFF traction control does it still happen?
Check for any critters/rodents under there?
Have you removed all the parts, and reinstalled them?

MY27FUSION

· #6 · 2 mo ago

are you turning the wheel in the video?

Wojtas

Discussion Starter · #7 · 2 mo ago

Thank you Guys for helping.

Now I feel like an idiot. We have found the culprit.

It turned out that this noise is made by brake pads that are slightly too loose 🤯.

So maybe as @maydk65 noticed, they should clip with extra pressure but for mine it was not necessary.
The strange thing is that it was confirmed with PowerStop dealer:

Power Stop Front and Rear K8975 Carbon-Fiber Ceramic Brake Pad with Drilled and Slotted Rotor Kit Z23

Rectangle Font Number Paper product Paper

maydk65 said:
Just remember when you are setting those brake pads on the front. It take a little extra pressure to set them in the "cup" of the caliper. You will swear it the metal clip won't fit, but just give some more pressure and it will go right on in.

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Reactions: 1

Wojtas

Discussion Starter · #8 · 2 mo ago

Wojtas said:
however I have some issue with my parking brake ( I will add this part tomorrow)

because of my stupidity I broke clamping motor/engine in the right rear brake.

I used forscan to eneter maintenace mode, but then by mistake I turn on exit porcedure and the piston popped out. We pushed manually the piston after being in maintenance mode again but engine is broke and I have to immidiatelly buy new rear right caliper with clamping motor/engine

when I turn on parking brake the alert is shown on the dashboard but after few try of release it finally release

I cleared all errors in forscan and it is clear. My mechanic confirmed that I broke clamping motor

I feel like a Moron 😔😔
Now, I am looking for used parts. I do not want to know how much it will cost from Ford dealer.

Reactions: 1

Wojtas

Discussion Starter · #9 · 2 mo ago

3

Font Automotive exterior Auto part Parallel Diagram

Automotive lighting Motor vehicle Automotive exterior Bumper Vehicle door

there is about 1mm loose (I have to get used to those knocks)

Automotive design Motor vehicle Automotive exterior Automotive lighting Auto part

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Reactions: 1

Bitten in '69

· #10 · 2 mo ago

Woj,
I may be mistaken, but shouldn't there be stainless steel clips inserted into the calipers that the pad ends ride in?
They would take up the space and prevent the pads from shifting.

Wojtas

Discussion Starter · #11 · 2 mo ago

2

Bitten in '69 said:
Woj,
I may be mistaken, but shouldn't there be stainless steel clips inserted into the calipers that the pad ends ride in?
They would take up the space and prevent the pads from shifting.

Hi @Bitten in '69 - can you tell me more please? What stainles steel clips? I thought the same, I saw this on the box. You mean these ones?

Product Automotive tire Font Tire Audio equipment

I asked the guys from the shop but they told me that it is just illustrative photo and this part is not in the set

Automotive tire Automotive lighting Automotive design Alloy wheel Vehicle brake

WTF???

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Wojtas

Discussion Starter · #12 · 2 mo ago

Can somebody else confirm this please? It is written *where applicable - so the question is if it is applicable in FFS

?

Font Audio equipment Auto part Automotive tire Electronic device

Someone who installed the same or similar kit? It makes complete sense.
These sounds freaking me out.

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Wojtas

Discussion Starter · #13 · 2 mo ago

I uploaded this photo above - this is the photo that I received from the brakes dealer - he claimed that those are the parts from the set
It seems that metal clips are not parts of this set

Font Diagram Auto part Event Eyewear

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Bitten in '69

· #14 · 2 mo ago

Woj,
I just checked the box of a set of Raybestos pads that I got for mine. Not needed yet. But, there are no clips withe these pads either. So, your pads may not have come with them. It is possible that they would be in a 'hardware kit' for Fusion brakes.
Fred

Reactions: 1

Bitten in '69

· #15 · 2 mo ago

Woj,
Checked Rockauto. They do sell front and rear hardware kits for Sport brakes. The clips look different than what was in your photo, but they still might be what you need.
Fred

Reactions: 1

Wojtas

Discussion Starter · #16 · 2 mo ago

I confirmed with Rockauto my set:

Automotive tire Font Rim Automotive wheel system Auto part

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Bitten in '69

· #17 · 2 mo ago

Okay, on the left side of your photo, under the pads are clips. Those are the same as the ones in the hardware kit. Were you able to install them?
Also, this is just an idea, but possible. I had ordered pads for a car (different vehicle). Went to install, didn't fit. Too long. If you can, measure the length of the backing plate on old and new. Make sure they match.
Fred

Reactions: 1

Wojtas

Discussion Starter · #18 · 2 mo ago

Bitten in '69 said:
Okay, on the left side of your photo, under the pads are clips. Those are the same as the ones in the hardware kit. Were you able to install them?
Also, this is just an idea, but possible. I had ordered pads for a car (different vehicle). Went to install, didn't fit. Too long. If you can, measure the length of the backing plate on old and new. Make sure they match.
Fred

Hi, I will change them for new ones. Honestly at first look they seems to be the same, so I did not change because my old ones are in red color and still looks tight. But I will try - good point. Next week I will measure the brake pads new vs old.
Simple ideas are always the best

!

I will let you know.

Wojtas

Discussion Starter · #19 · 2 mo ago

Bitten in '69 said:
Okay, on the left side of your photo, under the pads are clips. Those are the same as the ones in the hardware kit. Were you able to install them?
Also, this is just an idea, but possible. I had ordered pads for a car (different vehicle). Went to install, didn't fit. Too long. If you can, measure the length of the backing plate on old and new. Make sure they match.
Fred

@Bitten in '69

as if by the touch of a magic wand the knocking stopped... I owe you not only a virtual beer.🍺

I asked both mechanics (they know about my issue with knocking brake pads) and both said that it is not necessary to chnage metal clips... I have to change mechanics

Automotive lighting Automotive exterior Fender Bumper Auto part

lesson learned

"A man learns all his life and dies a fool"

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Downforce137

· #20 · 2 mo ago

i installed the r1 concepts brake kit yesterday, and only came with the large outer spring clip, and not the ones that contact the ends of the pad.

the red spring does look a bit deformed compared to the new one. hopefully this takes care of it.

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